Pub Date : 2026-02-15Epub Date: 2026-01-18DOI: 10.1016/j.jmapro.2026.01.055
Ce Xiao , Rongkang Han , Xue Dang , Yichen Han , Jinke Zhang , Pengyu Wang , Jinxin Liu , Yanjin Lu
Laser powder bed fusion (LPBF) processed Ti-1Al-8V-5Fe (Ti-185) alloy presents significant engineering potential as a high-strength, lightweight, and cost-effective beta-Ti titanium alloy. However, compared to LPBF-processed Ti alloys (e.g., Ti-6Al-4V), research on the microstructural and defect formation mechanisms of LPBF-processed Ti-185 alloy, and their effects on mechanical properties, remains limited. Defect analysis via X-ray computed tomography (X-CT) demonstrated that insufficient laser energy density leads to a large number of lack-of-fusion (LOF) defects, whereas excessive laser energy density produces smaller, highly spherical pores. In-situ X-CT tensile tests revealed that with insufficient laser energy, cracks initiate and propagate at the edges of large LOF defects under very small gauge strain, resulting in quasi-brittle fracture, while the high density of pores associated with excessive laser energy accelerates crack propagation, resulting primarily in reduced ductility rather than a decrease in strength. This study provides a comprehensive understanding of the influence of laser energy density on the mechanical behavior of LPBF-processed Ti-185 alloy, offering valuable insights for optimizing processing parameters and expanding its engineering applications.
{"title":"3D characterization of laser energy density effects on mechanical behavior in laser powder bed fused Ti-185 alloy via in-situ X-ray tomography","authors":"Ce Xiao , Rongkang Han , Xue Dang , Yichen Han , Jinke Zhang , Pengyu Wang , Jinxin Liu , Yanjin Lu","doi":"10.1016/j.jmapro.2026.01.055","DOIUrl":"10.1016/j.jmapro.2026.01.055","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) processed Ti-1Al-8V-5Fe (Ti-185) alloy presents significant engineering potential as a high-strength, lightweight, and cost-effective beta-Ti titanium alloy. However, compared to <span><math><mrow><mi>α</mi><mo>+</mo><mi>β</mi></mrow></math></span> LPBF-processed Ti alloys (e.g., Ti-6Al-4V), research on the microstructural and defect formation mechanisms of LPBF-processed Ti-185 alloy, and their effects on mechanical properties, remains limited. Defect analysis via X-ray computed tomography (X-CT) demonstrated that insufficient laser energy density leads to a large number of lack-of-fusion (LOF) defects, whereas excessive laser energy density produces smaller, highly spherical pores. In-situ X-CT tensile tests revealed that with insufficient laser energy, cracks initiate and propagate at the edges of large LOF defects under very small gauge strain, resulting in quasi-brittle fracture, while the high density of pores associated with excessive laser energy accelerates crack propagation, resulting primarily in reduced ductility rather than a decrease in strength. This study provides a comprehensive understanding of the influence of laser energy density on the mechanical behavior of LPBF-processed Ti-185 alloy, offering valuable insights for optimizing processing parameters and expanding its engineering applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 317-333"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024763","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-02-15Epub Date: 2026-01-15DOI: 10.1016/j.jmapro.2026.01.020
Daniel Dobras , Zbigniew Zimniak , Mateusz Dziubek
Aluminum alloys have high specific strength, which means that their use can result in a reduction in vehicle weight and thus their emissions. However, their formability at room temperature is low. A significant increase in the formability of strain-hardened aluminum alloys can be achieved by applying current pulses during their deformation. However, until now, it has not been possible to achieve this in sheet metal forming of aluminum alloys. This work shows that it is possible to increase the drawability of aluminum alloy sheets in the electrically-assisted deep drawing process. Eliminating the blank holder force during the process, using stainless steel dies and modular punch design enabled the heat transfer to be reduced and the appropriate temperature of the drawpiece to be obtained. Thanks to this, dynamic recovery was triggered while maintaining the mechanical properties of the material. The obtained results will allow the development of the electrically-assisted sheet metal forming, especially the deep drawing processes. The drawability of the material can be increased in these processes by using the economical method of applying current pulses.
{"title":"Plasticity improvement by pulsed electric current during sheet metal forming of Al-Mg alloy strips in different states of hardening","authors":"Daniel Dobras , Zbigniew Zimniak , Mateusz Dziubek","doi":"10.1016/j.jmapro.2026.01.020","DOIUrl":"10.1016/j.jmapro.2026.01.020","url":null,"abstract":"<div><div>Aluminum alloys have high specific strength, which means that their use can result in a reduction in vehicle weight and thus their emissions. However, their formability at room temperature is low. A significant increase in the formability of strain-hardened aluminum alloys can be achieved by applying current pulses during their deformation. However, until now, it has not been possible to achieve this in sheet metal forming of aluminum alloys. This work shows that it is possible to increase the drawability of aluminum alloy sheets in the electrically-assisted deep drawing process. Eliminating the blank holder force during the process, using stainless steel dies and modular punch design enabled the heat transfer to be reduced and the appropriate temperature of the drawpiece to be obtained. Thanks to this, dynamic recovery was triggered while maintaining the mechanical properties of the material. The obtained results will allow the development of the electrically-assisted sheet metal forming, especially the deep drawing processes. The drawability of the material can be increased in these processes by using the economical method of applying current pulses.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 166-175"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981201","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-02-15Epub Date: 2026-01-19DOI: 10.1016/j.jmapro.2026.01.054
Dongdong Liu , Haojie Zhu, Rui Shen, Fanghong Sun
Conventional diamond powders are mainly industrial diamond powders, typically produced by mechanically crushing methods, which possess irregular, randomly oriented and few edges, causing the lower cutting efficiency and service life. In this paper, uniform and consistently exposed micro-cutting edges were successfully fabricated on conventional diamond powders using hot filament chemical vapor deposition (HFCVD) method. Molecular dynamics (MD) software was used to simulate the multiple-powder scratching on silicon carbide (SiC) ceramics. Scratching simulation results suggest that micro-edge diamond powders produce finer scratch marks, reduce subsurface damage, exhibiting decreased scratching forces and temperatures. The scratching process analysis based on the scratching force results of MD simulation and numerical modeling illustrates that micro-edge diamond powders exert less average pressure on workpiece, resulting in lower material damage. CVD diamond powders under different growth conditions were fabricated by adjusting the deposition parameters, and the hardness of conventional diamond powders, shaped diamond powders and micro-edge diamond powders were compared through indentation tests. Conventional diamond powders undergo film growth, reshaping, micro-edge formation, and slight passivation with a significant reduction in graphite content and enhanced diamond purity as well as hardness throughout CVD growth. The polishing tests are conducted on SiC ceramic workpieces using prepared polishing slurries mixed diamond powders with organic solvents. Polished workpiece achieved a surface roughness value of Sa 4.6 μm reduced to Sa1.3 μm, and the material removal rate reached 4 mm3/min.
{"title":"Molecular dynamics simulation and polishing experimental investigation of CVD micro-edge diamond powders","authors":"Dongdong Liu , Haojie Zhu, Rui Shen, Fanghong Sun","doi":"10.1016/j.jmapro.2026.01.054","DOIUrl":"10.1016/j.jmapro.2026.01.054","url":null,"abstract":"<div><div>Conventional diamond powders are mainly industrial diamond powders, typically produced by mechanically crushing methods, which possess irregular, randomly oriented and few edges, causing the lower cutting efficiency and service life. In this paper, uniform and consistently exposed micro-cutting edges were successfully fabricated on conventional diamond powders using hot filament chemical vapor deposition (HFCVD) method. Molecular dynamics (MD) software was used to simulate the multiple-powder scratching on silicon carbide (SiC) ceramics. Scratching simulation results suggest that micro-edge diamond powders produce finer scratch marks, reduce subsurface damage, exhibiting decreased scratching forces and temperatures. The scratching process analysis based on the scratching force results of MD simulation and numerical modeling illustrates that micro-edge diamond powders exert less average pressure on workpiece, resulting in lower material damage. CVD diamond powders under different growth conditions were fabricated by adjusting the deposition parameters, and the hardness of conventional diamond powders, shaped diamond powders and micro-edge diamond powders were compared through indentation tests. Conventional diamond powders undergo film growth, reshaping, micro-edge formation, and slight passivation with a significant reduction in graphite content and enhanced diamond purity as well as hardness throughout CVD growth. The polishing tests are conducted on SiC ceramic workpieces using prepared polishing slurries mixed diamond powders with organic solvents. Polished workpiece achieved a surface roughness value of Sa 4.6 μm reduced to Sa1.3 μm, and the material removal rate reached 4 mm<sup>3</sup>/min.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 396-408"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024733","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-02-15Epub Date: 2026-01-19DOI: 10.1016/j.jmapro.2026.01.043
Jianbin Zhan , Ruijing Ma , Haodong Wang , Ke Zhu , Shengqian Wang , Liang Zhu , Xuan Liang , Shiyue Guo , Huajun Cao , Kun Li
In NiTi shape-memory alloys, laser powder bed fusion (L-PBF) is used to create spatial microstructural domains, which are jointly controlled by grain size and aging-induced Ni4Ti3 precipitates, allowing a 3D structure to exhibit time-dependent martensitic transformation under stress. This programmable time dependency constitutes 4D printing and enables component-level functional customization. Leveraging this concept, we fabricate a porous NiTi alloy with a high specific cooling capacity for elastocaloric (eC) refrigeration, where two key targets are the specific surface area (S/V) and the force-to-heat conversion ratio (ΔTad/F). These metrics are co-controlled by lattice architecture and microstructure. At the macroscopic scale, four L-PBF lattice designs, strut-based and triply periodic minimal surface (TPMS), are created to tailor the theoretical S/V and ΔTad/F. At the microscopic scale, laser parameters and aging processes modulate grain size and Ni4Ti3 precipitates, tuning the intrinsic eC effect (ΔTad). Results show that single-scale optimization cannot maximize both S/V and ΔTad/F simultaneously. During cooling, the martensite volume fraction (MVF) predominantly governs ΔTad, and its distribution, typically concentrated at pore connections, can be directed by lattice design. Geometry-defined pore morphology and size set stress concentrations, which, together with manufacturing defects under different laser conditions, can trigger premature failure and reduce performance relative to theoretical predictions. A 4D-printing strategy based on the skeletal Gyroid architecture synergistically enhances both metrics, achieving S/V = 12.1 mm−1 and ΔTad/F = 15.7 K·kN−1. These findings provide valuable insights into the manufacturing of lattice-structured NiTi alloys for eC refrigeration.
{"title":"Enhancing the specific cooling capacity of porous elastocaloric NiTi refrigerants via laser 4D printing","authors":"Jianbin Zhan , Ruijing Ma , Haodong Wang , Ke Zhu , Shengqian Wang , Liang Zhu , Xuan Liang , Shiyue Guo , Huajun Cao , Kun Li","doi":"10.1016/j.jmapro.2026.01.043","DOIUrl":"10.1016/j.jmapro.2026.01.043","url":null,"abstract":"<div><div>In NiTi shape-memory alloys, laser powder bed fusion (L-PBF) is used to create spatial microstructural domains, which are jointly controlled by grain size and aging-induced Ni<sub>4</sub>Ti<sub>3</sub> precipitates, allowing a 3D structure to exhibit time-dependent martensitic transformation under stress. This programmable time dependency constitutes 4D printing and enables component-level functional customization. Leveraging this concept, we fabricate a porous NiTi alloy with a high specific cooling capacity for elastocaloric (eC) refrigeration, where two key targets are the specific surface area (<em>S</em>/<em>V</em>) and the force-to-heat conversion ratio (Δ<em>T</em><sub><em>ad</em></sub>/<em>F</em>). These metrics are co-controlled by lattice architecture and microstructure. At the macroscopic scale, four L-PBF lattice designs, strut-based and triply periodic minimal surface (TPMS), are created to tailor the theoretical <em>S</em>/<em>V</em> and Δ<em>T</em><sub><em>ad</em></sub>/<em>F</em>. At the microscopic scale, laser parameters and aging processes modulate grain size and Ni<sub>4</sub>Ti<sub>3</sub> precipitates, tuning the intrinsic eC effect (Δ<em>T</em><sub><em>ad</em></sub>). Results show that single-scale optimization cannot maximize both <em>S</em>/<em>V</em> and Δ<em>T</em><sub><em>ad</em></sub>/<em>F</em> simultaneously. During cooling, the martensite volume fraction (MVF) predominantly governs Δ<em>T</em><sub><em>ad</em></sub>, and its distribution, typically concentrated at pore connections, can be directed by lattice design. Geometry-defined pore morphology and size set stress concentrations, which, together with manufacturing defects under different laser conditions, can trigger premature failure and reduce performance relative to theoretical predictions. A 4D-printing strategy based on the skeletal Gyroid architecture synergistically enhances both metrics, achieving S/V = 12.1 mm<sup>−1</sup> and Δ<em>T</em><sub><em>ad</em></sub>/<em>F</em> = 15.7 K·kN<sup>−1</sup>. These findings provide valuable insights into the manufacturing of lattice-structured NiTi alloys for eC refrigeration.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 361-376"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024732","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Surface topography critically governs the mechanical performance—particularly fatigue resistance-of components fabricated via laser powder bed fusion (LPBF). To advance the understanding of how parameters govern surface formation, a comprehensive multi-physics model was developed, integrating random powder deposition (Discrete Element Method), laser-material interaction and melt pool (MP) dynamics (Finite Volume Method). The framework integrates surface-active elements with a strongly coupled laser tracing model, leading to two critical advances: first, it provides new insights into the role of surface-active elements in MP dynamics; second, it successfully reproduces, the complex formation mechanisms of varying surface topography in multi-track scans by constant surface-active elements: 1) impurity effects: explicitly modeling sulfur and oxygen interactions within the MP, and reveal these elements substantially degrade surface quality through complex thermo-physics mechanisms. Quantitative analysis reveals sulfur exerts a 2.74× stronger influence on surface peak formation than oxygen when concentrations decrease tenfold (S: 0.3 → 0.03%; O: 0.1 → 0.01%), establishing its dominance in surface topography evolution. However, at ultralow oxygen‑sulfur concentrations, surface topography converges to identical configurations. 2) scanning parameter effects: a coupled analysis of scanning parameter effects-encompassing strategy, speed, and hatch spacing-on non-uniform temperature field evolution is conducted, evaluating-i): energy absorptivity dynamics, ii) surface-induced porosity, iii) inter-track interaction mechanisms, iv) Plateau-Rayleigh instabilities and v) interaction of melt rate, melt flow velocity, inertia and surface tension on surface topography. This study reveals that localized peaks within the MP disrupt laser beam reflection, altering MP dynamics. Furthermore, irregular surface peaks and valleys contribute to the formation of various surface pore types. Critically, during multi-track process, the coupling between scanning strategy and speed generates heterogeneous thermal fields that significantly alter subsequent surface evolution. Our paper provides theoretical guides to help users of additive manufacturing optimize the topography of parts.
{"title":"Multi-physics investigation on the influence of impurity elements and scanning parameters on the surface topography in laser powder bed fusion","authors":"Xingyue Zhai , Ziad Moumni , Zhidong Zhang , Feifan Li , Shuheng Wang , Xiaojun Gu , Jihong Zhu , Weihong Zhang","doi":"10.1016/j.jmapro.2026.01.011","DOIUrl":"10.1016/j.jmapro.2026.01.011","url":null,"abstract":"<div><div>Surface topography critically governs the mechanical performance—particularly fatigue resistance-of components fabricated via laser powder bed fusion (LPBF). To advance the understanding of how parameters govern surface formation, a comprehensive multi-physics model was developed, integrating random powder deposition (Discrete Element Method), laser-material interaction and melt pool (MP) dynamics (Finite Volume Method). The framework integrates surface-active elements with a strongly coupled laser tracing model, leading to two critical advances: first, it provides new insights into the role of surface-active elements in MP dynamics; second, it successfully reproduces, the complex formation mechanisms of varying surface topography in multi-track scans by constant surface-active elements: 1) impurity effects: explicitly modeling sulfur and oxygen interactions within the MP, and reveal these elements substantially degrade surface quality through complex thermo-physics mechanisms. Quantitative analysis reveals sulfur exerts a 2.74× stronger influence on surface peak formation than oxygen when concentrations decrease tenfold (S: 0.3 → 0.03%; O: 0.1 → 0.01%), establishing its dominance in surface topography evolution. However, at ultralow oxygen‑sulfur concentrations, surface topography converges to identical configurations. 2) scanning parameter effects: a coupled analysis of scanning parameter effects-encompassing strategy, speed, and hatch spacing-on non-uniform temperature field evolution is conducted, evaluating-i): energy absorptivity dynamics, ii) surface-induced porosity, iii) inter-track interaction mechanisms, iv) Plateau-Rayleigh instabilities and v) interaction of melt rate, melt flow velocity, inertia and surface tension on surface topography. This study reveals that localized peaks within the MP disrupt laser beam reflection, altering MP dynamics. Furthermore, irregular surface peaks and valleys contribute to the formation of various surface pore types. Critically, during multi-track process, the coupling between scanning strategy and speed generates heterogeneous thermal fields that significantly alter subsequent surface evolution. Our paper provides theoretical guides to help users of additive manufacturing optimize the topography of parts.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 18-38"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145950430","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-02-15Epub Date: 2026-01-18DOI: 10.1016/j.jmapro.2026.01.044
Guanzhong Hu, Wenpan Li, Rujing Zha, Ping Guo
Directed energy deposition (DED), a metal additive manufacturing process, is highly susceptible to process-induced defects such as geometric deviations, lack of fusion, and poor surface finish. This work presents a build-height-synchronized fringe projection system for in-situ, layer-wise surface reconstruction of laser-DED components, achieving a reconstruction accuracy of . From the reconstructed 3D morphology, two complementary geometry-based point-cloud metrics are introduced: local point density, which highlights poor surface finish, and normal-change rate, which identifies lack-of-fusion features. These methods enable automated, annotation-free identification of common deposition anomalies directly from reconstructed surfaces, without the need for manual labeling. By directly linking geometric deviation to defect formation, the approach enables precise anomaly localization and advances the feasibility of closed-loop process control. This work establishes fringe projection as a practical tool for micrometer-scale monitoring in DED, bridging the gap between process signatures and part geometry for certifiable additive manufacturing.
{"title":"Layer-wise anomaly detection in directed energy deposition using high-fidelity fringe projection profilometry","authors":"Guanzhong Hu, Wenpan Li, Rujing Zha, Ping Guo","doi":"10.1016/j.jmapro.2026.01.044","DOIUrl":"10.1016/j.jmapro.2026.01.044","url":null,"abstract":"<div><div>Directed energy deposition (DED), a metal additive manufacturing process, is highly susceptible to process-induced defects such as geometric deviations, lack of fusion, and poor surface finish. This work presents a build-height-synchronized fringe projection system for in-situ, layer-wise surface reconstruction of laser-DED components, achieving a reconstruction accuracy of <span><math><mrow><mo>±</mo><mtext>46</mtext><mspace></mspace><mtext>µm</mtext></mrow></math></span>. From the reconstructed 3D morphology, two complementary geometry-based point-cloud metrics are introduced: local point density, which highlights poor surface finish, and normal-change rate, which identifies lack-of-fusion features. These methods enable automated, annotation-free identification of common deposition anomalies directly from reconstructed surfaces, without the need for manual labeling. By directly linking geometric deviation to defect formation, the approach enables precise anomaly localization and advances the feasibility of closed-loop process control. This work establishes fringe projection as a practical tool for micrometer-scale monitoring in DED, bridging the gap between process signatures and part geometry for certifiable additive manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 334-346"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024730","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-02-15Epub Date: 2026-01-17DOI: 10.1016/j.jmapro.2026.01.013
Yue Zhang , Xian Wang , Tao Wang , Changyou Xu , Tao Shi , Penghui Guo , Xiaocong He , Lin Li
The growing demand for lightweight, high-performance joints in aerospace is limited by cracking and non-uniformity during high-strength plate clinching. To overcome these challenges, this study employs ultrasonic vibration-assisted clinching of TA1 titanium alloy, focusing on its forming performance, microstructure, and mechanical properties within the ultrasonic vibration-assisted clinching process. Test results indicate that under ultrasonic vibration-assisted clinching conditions with an amplitude of 10.58 μm, the riveting force is reduced by 23.7% compared to conventional processes. Single-factor experiments determined that the optimal joint clinching performance was achieved with an optimized punch and die combination, a clinching speed of 300 mm/min, and an amplitude of 10.58 μm. Electron backscatter diffraction and microhardness analysis revealed that ultrasonic vibration promoted dynamic recrystallization and grain boundary migration, resulting in grain refinement and improved texture orientation distribution. This enhanced the material's plastic flow capability and structural uniformity. Compared to conventional processes, microhardness increased by 18.72% and 11.75% for the upper and lower plates, respectively, enhancing joint stiffness and load-bearing capability. Regarding mechanical properties, the tensile strength, cross-peel strength, and T-peel strength of ultrasonically assisted clinched joints improved by 12.5%, 16.9%, and 32.88%, respectively, with significantly enhanced energy absorption capacity. Fatigue testing revealed that ultrasonically assisted clinched joints exhibited longer lifetimes than conventional imprint joints across multiple load levels. Fracture surface and energy spectrum analyses indicated that fatigue cracks primarily originated in the micro-wear zone between plates. Simultaneously, ultrasonic vibration suppressed rapid crack propagation, demonstrating the process's ability to effectively delay crack evolution and enhance structural reliability. In summary, ultrasonic vibration-assisted clinching reduces forming energy consumption, optimizes microstructural organization, and enhances joint mechanical properties. This technique offers an efficient, low-carbon solution for lightweight connections in high-strength titanium alloys and other difficult-to-form materials, holding significant engineering implications for aerospace structural manufacturing.
{"title":"Ultrasonic vibration-enhanced clinching process for TA1 titanium alloy: Forming characteristics and mechanical properties","authors":"Yue Zhang , Xian Wang , Tao Wang , Changyou Xu , Tao Shi , Penghui Guo , Xiaocong He , Lin Li","doi":"10.1016/j.jmapro.2026.01.013","DOIUrl":"10.1016/j.jmapro.2026.01.013","url":null,"abstract":"<div><div>The growing demand for lightweight, high-performance joints in aerospace is limited by cracking and non-uniformity during high-strength plate clinching. To overcome these challenges, this study employs ultrasonic vibration-assisted clinching of TA1 titanium alloy, focusing on its forming performance, microstructure, and mechanical properties within the ultrasonic vibration-assisted clinching process. Test results indicate that under ultrasonic vibration-assisted clinching conditions with an amplitude of 10.58 μm, the riveting force is reduced by 23.7% compared to conventional processes. Single-factor experiments determined that the optimal joint clinching performance was achieved with an optimized punch and die combination, a clinching speed of 300 mm/min, and an amplitude of 10.58 μm. Electron backscatter diffraction and microhardness analysis revealed that ultrasonic vibration promoted dynamic recrystallization and grain boundary migration, resulting in grain refinement and improved texture orientation distribution. This enhanced the material's plastic flow capability and structural uniformity. Compared to conventional processes, microhardness increased by 18.72% and 11.75% for the upper and lower plates, respectively, enhancing joint stiffness and load-bearing capability. Regarding mechanical properties, the tensile strength, cross-peel strength, and T-peel strength of ultrasonically assisted clinched joints improved by 12.5%, 16.9%, and 32.88%, respectively, with significantly enhanced energy absorption capacity. Fatigue testing revealed that ultrasonically assisted clinched joints exhibited longer lifetimes than conventional imprint joints across multiple load levels. Fracture surface and energy spectrum analyses indicated that fatigue cracks primarily originated in the micro-wear zone between plates. Simultaneously, ultrasonic vibration suppressed rapid crack propagation, demonstrating the process's ability to effectively delay crack evolution and enhance structural reliability. In summary, ultrasonic vibration-assisted clinching reduces forming energy consumption, optimizes microstructural organization, and enhances joint mechanical properties. This technique offers an efficient, low-carbon solution for lightweight connections in high-strength titanium alloys and other difficult-to-form materials, holding significant engineering implications for aerospace structural manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 298-316"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024766","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-02-15Epub Date: 2026-01-14DOI: 10.1016/j.jmapro.2026.01.003
Xiaoxia Qi , Yanle Li , Jiyu Du , Weiguang Fan , Yunjian Bai , Heng Chen , Fangyi Li
Continuous chain-like Laves phase is a significant factor leading to the failure of additively manufactured IN 718 alloy, resulting in the restricted application in critical aerospace components. To obtain high performance for IN 718 alloy, a novel processing strategy of laser directed energy deposition (LDED) combining bi-dimensional ultrasonic vibration (UV) and double aging (DA) is proposed to regulate Laves phase and γ″ phase. The DA-treated IN 718 sample with UV (UV-718A) achieves an ultimate tensile strength of 1389.7 ± 22.5 MPa and an elongation of 14.0 % ± 0.5 %, which are increased by 9.13 % and 33.3 %, respectively, compared to the DA-treated IN 718 without UV (NU-718A). Notably, the contributions of UV to yield strength before and after DA were 70.2 MPa and 113.7 MPa, respectively. The outstanding performance of the UV-718A sample was mainly attributed to refined grains and granular Laves phase surrounded by uniformly distributed γ′/γ″ phases. The finer grains and granular Laves phases result from the homogenization of alloy composition under UV, which promotes more uniform precipitation of γ″ phase (the distribution width expands by 80.4 %) during subsequent DA. Under the UV effect, the chain-like Laves phase is transformed into granular structures, and its content is reduced by 30.8 %, which contributes to improved ductility. Furthermore, fractographic analysis reveals that the failure mechanism for both the NU-718A and UV-718A samples is microvoids aggregation-induced fracture, where microvoids are caused by self-fragmentation of chain-like Laves phases and debonding of granular Laves phases. This research provides a processing strategy for high-performance critical aerospace components.
{"title":"Strengthening mechanism of IN 718 alloy fabricated by ultrasonic vibration-assisted laser directed energy deposition with heat treatment","authors":"Xiaoxia Qi , Yanle Li , Jiyu Du , Weiguang Fan , Yunjian Bai , Heng Chen , Fangyi Li","doi":"10.1016/j.jmapro.2026.01.003","DOIUrl":"10.1016/j.jmapro.2026.01.003","url":null,"abstract":"<div><div>Continuous chain-like Laves phase is a significant factor leading to the failure of additively manufactured IN 718 alloy, resulting in the restricted application in critical aerospace components. To obtain high performance for IN 718 alloy, a novel processing strategy of laser directed energy deposition (LDED) combining bi-dimensional ultrasonic vibration (UV) and double aging (DA) is proposed to regulate Laves phase and γ″ phase. The DA-treated IN 718 sample with UV (UV-718A) achieves an ultimate tensile strength of 1389.7 ± 22.5 MPa and an elongation of 14.0 % ± 0.5 %, which are increased by 9.13 % and 33.3 %, respectively, compared to the DA-treated IN 718 without UV (NU-718A). Notably, the contributions of UV to yield strength before and after DA were 70.2 MPa and 113.7 MPa, respectively. The outstanding performance of the UV-718A sample was mainly attributed to refined grains and granular Laves phase surrounded by uniformly distributed γ′/γ″ phases. The finer grains and granular Laves phases result from the homogenization of alloy composition under UV, which promotes more uniform precipitation of γ″ phase (the distribution width expands by 80.4 %) during subsequent DA. Under the UV effect, the chain-like Laves phase is transformed into granular structures, and its content is reduced by 30.8 %, which contributes to improved ductility. Furthermore, fractographic analysis reveals that the failure mechanism for both the NU-718A and UV-718A samples is microvoids aggregation-induced fracture, where microvoids are caused by self-fragmentation of chain-like Laves phases and debonding of granular Laves phases. This research provides a processing strategy for high-performance critical aerospace components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 107-118"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981203","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-02-15Epub Date: 2026-01-15DOI: 10.1016/j.jmapro.2026.01.018
Ye Tian , Wen Zhang , Xincun Zhuang , Zhen Zhao
The limited formability of age-hardened aluminum alloys at room temperature presents significant manufacturing challenges for fabricating complex components. This study systematically investigates the synergistic enhancement mechanism of through-thickness stress and forming temperature on the formability of age-hardened 2219 aluminum alloy. A flat-bottom stretching test platform integrated with through-thickness stress control and temperature regulation was developed to evaluate the limiting forming height (LFH) under varying thermo-mechanical conditions (75–225 °C, 0–180 MPa). Contrary to the commonly assumed monotonic relationship, the results reveal a critical threshold of through-thickness stress (Pc) for significant formability improvement. And the PC decreases as the forming temperature increases. Below Pc, LFH exhibited negligible improvement. When stress exceeded Pc, LFH increased sharply. As the stress continues to increase, the enhancement effect on LFH gradually diminishes. Microstructural analysis indicated that through-thickness stress effectively reduces damage accumulation by inhibiting the fragmentation of precipitates and the growth of voids. The theoretical predictions for PC closely align with experimental results under conditions where stress triaxiality shifts from positive to negative values. In hole-flanging applications, a through-thickness stress of 120 MPa increased flange height by 17.4% and reduces required forming temperatures by 25 °C. These findings provide not only a fundamental insight into the non-linear effect of through-thickness stress but also practical strategies for efficient forming of age-hardened aluminum alloys.
{"title":"Enhanced formability of age-hardened 2219 aluminum alloy: role of through-thickness stress and temperature synergy","authors":"Ye Tian , Wen Zhang , Xincun Zhuang , Zhen Zhao","doi":"10.1016/j.jmapro.2026.01.018","DOIUrl":"10.1016/j.jmapro.2026.01.018","url":null,"abstract":"<div><div>The limited formability of age-hardened aluminum alloys at room temperature presents significant manufacturing challenges for fabricating complex components. This study systematically investigates the synergistic enhancement mechanism of through-thickness stress and forming temperature on the formability of age-hardened 2219 aluminum alloy. A flat-bottom stretching test platform integrated with through-thickness stress control and temperature regulation was developed to evaluate the limiting forming height (LFH) under varying thermo-mechanical conditions (75–225 °C, 0–180 MPa). Contrary to the commonly assumed monotonic relationship, the results reveal a critical threshold of through-thickness stress (<em>P</em>c) for significant formability improvement. And the <em>P</em><sub>C</sub> decreases as the forming temperature increases. Below <em>P</em>c, LFH exhibited negligible improvement. When stress exceeded <em>P</em>c, LFH increased sharply. As the stress continues to increase, the enhancement effect on LFH gradually diminishes. Microstructural analysis indicated that through-thickness stress effectively reduces damage accumulation by inhibiting the fragmentation of precipitates and the growth of voids. The theoretical predictions for <em>P</em><sub>C</sub> closely align with experimental results under conditions where stress triaxiality shifts from positive to negative values. In hole-flanging applications, a through-thickness stress of 120 MPa increased flange height by 17.4% and reduces required forming temperatures by 25 °C. These findings provide not only a fundamental insight into the non-linear effect of through-thickness stress but also practical strategies for efficient forming of age-hardened aluminum alloys.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 176-187"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981207","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-02-15Epub Date: 2026-01-14DOI: 10.1016/j.jmapro.2026.01.024
Lang Wu , Jun Luo , Yunlong Zhou , Yi Zhou , Shengnan Lv , Lehua Qi
Pore defects in metal droplet deposition, caused by gas entrainment, significantly degrade the reliability of printed bumps. While prior research has primarily addressed gas entrapment at the substrate interface leading to bottom pores, this study identifies a novel issue: droplet-top ambient gas entrainment causing internal pores within the bumps. To explore this phenomenon, we conducted bump printing experiments under varying substrate temperatures and impact velocities, inducing diverse gas-liquid interface behaviors. A three-dimensional numerical model, developed using the VOF method, analyzed the two-phase gas-liquid flow and solidification interface evolution within the droplet. Quantitative analysis, combining one-dimensional heat conduction and gas cavity collapse theories, revealed a strong link between internal pore formation and the thermodynamic coupling ratio of gas cavity retraction, λcav—defined as the ratio of gas cavity retraction timescale (τcav) to solidification timescale (τsol). Higher λcav values increase viscous shear forces, impeding gas cavity retraction and promoting solidification during slow retraction, thereby generating internal pore defects. To address this defect, we developed a “Thermal-Impact dual-field regulated printing” strategy, successfully printing a bump array free of internal pore defects on a chip. These findings enhance understanding of pore formation mechanisms in droplet-based additive manufacturing and provide practical elimination strategies, especially for flip-chip bonding applications.
{"title":"Internal pores in printed metal bumps: evolution mechanism and elimination strategy","authors":"Lang Wu , Jun Luo , Yunlong Zhou , Yi Zhou , Shengnan Lv , Lehua Qi","doi":"10.1016/j.jmapro.2026.01.024","DOIUrl":"10.1016/j.jmapro.2026.01.024","url":null,"abstract":"<div><div>Pore defects in metal droplet deposition, caused by gas entrainment, significantly degrade the reliability of printed bumps. While prior research has primarily addressed gas entrapment at the substrate interface leading to bottom pores, this study identifies a novel issue: droplet-top ambient gas entrainment causing internal pores within the bumps. To explore this phenomenon, we conducted bump printing experiments under varying substrate temperatures and impact velocities, inducing diverse gas-liquid interface behaviors. A three-dimensional numerical model, developed using the VOF method, analyzed the two-phase gas-liquid flow and solidification interface evolution within the droplet. Quantitative analysis, combining one-dimensional heat conduction and gas cavity collapse theories, revealed a strong link between internal pore formation and the thermodynamic coupling ratio of gas cavity retraction, <em>λ</em><sub>cav</sub>—defined as the ratio of gas cavity retraction timescale (<em>τ</em><sub>cav</sub>) to solidification timescale (<em>τ</em><sub>sol</sub>). Higher <em>λ</em><sub>cav</sub> values increase viscous shear forces, impeding gas cavity retraction and promoting solidification during slow retraction, thereby generating internal pore defects. To address this defect, we developed a “Thermal-Impact dual-field regulated printing” strategy, successfully printing a bump array free of internal pore defects on a chip. These findings enhance understanding of pore formation mechanisms in droplet-based additive manufacturing and provide practical elimination strategies, especially for flip-chip bonding applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 150-165"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981209","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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